Internship Report 2018

(Mechanical Maintenance)

Submitted By:
Rana
Muhammad Waqar Ahmed

University Of Engineering & Technology, Lahore

Contents
Acknowledgement ...................................................................................... 3
Summary: ................................................................................................... 4
Introduction: .............................................................................................. 5
Plant Description: ....................................................................................... 5
Utilities: ...................................................................................................... 5
Ammonia: ................................................................................................... 6
Urea:........................................................................................................... 6
Sections Covered: ....................................................................................... 7
Equipment Maintenance Urea I: ................................................................. 7
Valves: ........................................................................................................ 7
Pipe Fittings: .................................................. Error! Bookmark not defined.
Heat exchangers: ...................................................................................... 12
Heat Exchanger Types on the Basis of Construction ................................. 14
Types of baffles ........................................................................................ 14
Machine Shop: .......................................................................................... 15
Machinery Maintenance Ammonia-II: ...................................................... 16
Centrifugal Pumps: ................................................................................... 16
Positive Displacement Compressor:.......................................................... 18
Reciprocating Piston Compressors............................................................ 18
Rotary Screw Compressors: ...................................................................... 18
Rotary Vane Compressors: ....................................................................... 19
Lobed compressor: ................................................................................... 19
Liquid Piston compressor: ........................................................................ 19
Difference between positive and non-positive compressors .................... 19
Bearings:................................................................................................... 20
Bearing Types and Application.................................................................. 21
Tapered Roller Bearings:........................................................................... 21

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Spherical Roller Bearings: ......................................................................... 21
Health Safety and Environment: ............................................................... 22
Conclusion: ............................................................................................... 22

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 Acknowledgement

Alhamdulillah, I have completed my

internship at Fauji Fertilizer Company and I
would like to thank FFC for providing me a
chance to do internship in this company. I
would like to thank all of management and
staff members for devoting their special
time throughout the internship tenure. I am
also grateful to Engr. M. Zaryab for
providing an excellent learning opportunity
and getting into technical practicalities of
equipment maintenance section. Special
thanks to Engr. Adnan for indulging me into
basics of engineering and for helping to
develop basic professional attitude. At the
end I am again thankful to FFC for providing
this opportunity.

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 Summary:
This is the report submitted to the relevant university department for
the internship. It is about the internship completed in Mechanical
Maintenance Department of FFC. The report starts with the introduction of
Fauji Fertilizer Company introducing its importance to the fertilizer industry
of the country. There are three plants of FFC that are currently functional
excluding the FFBL. FFC produces around 60% of the total production of urea
in Pakistan. The report focusses FFC Goth Machhi plant.
The report focusses on the plant components in accordance with the
learning objectives. Plant is described in terms of classification as utilities,
urea and ammonia sections briefly. Onwards, the sections of the plant
covered, according to the training plan provided, are discussed one by one
and the equipment included in the internship module is described concisely.
The sections included equipment ammonia-II, machinery ammonia-I.

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Introduction:
Fauji Fertilizers Company is one of the biggest fertilizers’ producers of
Pakistan. Fauji Foundation is the major stake holder of this company.
Currently there are three plants working for urea manufacture, two at Goth
Machhi and one at Mirpur Mathelo. The Brand name under which the
produced fertilizer is marketed is “Sona Urea”. Goth Machhi Plant 1 became
commission on June 14, 1982 whereas Goth Machhi Plant 2 became
commission on March 21, 1993. Mirpur Mathelo Plant was already
functional when Fauji Foundation became the major shareholder.
FFC produces about 60% of the total Urea produced in Pakistan. For Goth
Machhi plant site The Urea production capacity of Plant 1 and Plant 2 are
2105 tons/day and 1925 tons/day respectively. Both the plants were
designed by SNAMPROGETTI SPA, Italy.
This report is focused on the Goth Machhi Plant site.
Besides the main working sections the plant site boasts a complete
Technical Training Facility, which includes a Library, many Laboratories and
demonstration Facilities. It is intended to provide Training to the Interns.
Residential Colonies have also been developed for the management and the
staff members (club) which are equipped with all the modern facilities that
include sporting, messing and other basic and entertainment facilities.

Plant Description:
Functionally, both the plants, plant I and plant II, are distributed into
three main parts; ammonia section, urea section and utilities. A brief
description of all of them is given below.
Utilities:
This section is related to the resources that are needed by both the urea and
the ammonia sections for their functioning. The utilities managed by this
section are treated water, cooling water, power and steam. The natural

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 resources used by this section are natural gas for power and steam
generation and raw water for demineralized water and cooling water.
Power:
Power is generated through two gas turbines that use natural gas for
their functioning. The total power generation capacity of these gas turbines
is about 36MW.
Steam:
The gases coming out of the gas turbines are at a very high temperature so
instead of discharging them directly to the atmosphere the thermal energy
of those gases is used to produce steam which is then used to drive steam
turbines.
Cooling water:
Water is the cooling fluid used most often in the plant. Cooling water serves
this purpose.
Treated Water:
Water is treated to be used for reaction purposes, and also as the cooling
water for exchangers etc.
Ammonia:
Ammonia plant is related only to the production of Ammonia and
carbon dioxide. The resources used are natural gas, air and process steam.
First process is reforming of natural gas that produces carbon dioxide and
hydrogen. CO2 is compressed and sent for usage in the urea section,
whereas, the hydrogen is then reacted with nitrogen in the air to produce
ammonia. The ammonia is stored in the ammonia storage unit which is
common for both the plants. Total ammonia production for plant I and
plant II is 1220 tons/day and 1100 tons/day respectively.

Urea:
This section of the plant is related to urea production. The resources
used are all the utilities available from the utilities department and carbon

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dioxide and ammonia from the ammonia section. The reaction between
ammonia and carbon dioxide occurs to produce ammonium carbamate
which changes to urea on losing water. After the reaction in the reactor the
urea is removed from the mixture and sent to be prilled. From the mixture
separated the gases like ammonia and carbon dioxide are removed and then
used again for the reaction. Most of the part of the plant is related to
recovery of these chemicals. The urea from the prilling tower is sent to the
urea storage from where it is taken to the bagging section where it is bagged
and then shipped across the country or stored in the storage. The total
production of urea from plant I and plant II is 2105 tons/day and 1925
tons/day respectively.

Sections Covered:
The following sections were covered for the given objectives.
Equipment Maintenance Ammonia ll:
This section is related stationary parts (valve, pipes) of the plant 2
ammonia section. All the maintenance and repair of this area is the
responsibility of this section.
Objective:
Study of Valves, Heat Exchangers, Pipe Fittings and materials used for
fertilizer plant
Valves:
Valves are the devices used in piping systems to control the flow of
fluids. The may be used to completely open or shut off the flow or may be
used to control the flow rate in throttling position. Valves may be classified
in a number of ways but the following classification is the most universally
used.

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 Following are the types of valves being used in the plant.
Gate Valves: Used for complete opening and complete shutting off the
line

Parts of Gate Valves:

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 Globe Valves: Used for throttling i-e controlling the
flow by controlling the opening
Parts of Globe Valve:

Plug Valves:It is used for quick

complete opening and quick complete closing.

Parts of Plug valves:

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Check Valves: Used to permit flow in only one direction

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Ball Valve: Used like a plug valve

Butterfly valve: Used for low pressure service, where

leakage is unimportant. Normally for large diameter
lines

Parts of Butterfly Valve:

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 Heat exchangers:
Heat exchangers are devices that are used to transfer heat between two
fluids due to a difference of temperature.
Direct Contact heat exchangers:
These heat exchangers permit direct contact of fluids for the heat transfer
like cooling towers.
Non-direct contact heat exchangers:
These exchangers don’t allow direct contact. There are two main types of
heat exchangers that are mostly used in the industry. There may be others
but are not widely used here.
I. Shell and tube heat exchangers:
These heatexchangers have a shell and a group of tubes inside the shell. One
fluid flows inside the tubes and the other flows inside the shell outside the
tubes. The heat is transferred through the tube walls. These are the most
widely used type of heat exchangers in the industry.

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II. Plate type heat exchangers:
These heat exchangers are very high efficiency heat exchangers with a lot of
heat transfer area per unit volume of the heat exchanger. The construction
includes a lot of plates piled one above the other and channels made
between them to permit the flow of fluids. The fluid move between
alternating channels between the plates and exchange heat through the
plates

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 Very important type of heat exchangers use in Plant II of FFC G.M.
Main advantage it that you can use it everywhere to change the heat
transfer rate whenever you want to change.
Heat Exchanger Types on the Basis of Construction

Types of baffles

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Machine Shop:
Machine shop is the workshop where are the operations related to
machining of mechanical components are carried out. With fabrication shop
this workshop makes a center for most of the altering operations to the
mechanical components of the plants. Besides machining the plant
components for maintenance work is also done on manufacture of some
components named as special projects.
Workshop contains all the standard facilities and utilities that should be
present in a machine shop. Safety and quality principles during the work are
followed rigidly. The work is done through work order documentation which
contains all the technical details and office record documents.
Objective:
Lathe, milling, drilling and other machines capability and working
There are many machines present in this shop each having its own purpose
or operations it can perform.

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Bench Drilling: Used to create holes in a part which may be threaded
afterwards
Power Hacksaw: Used to cut long bars to desired length
Vertical Lathe: A lathe machine that handles large parts and has a vertical
axis of rotation
Boring Machine: Works like a milling machine but can handle very large
parts. Tools are like that of a milling machine and working principle is also
quite the same.
Balancing Machine: Used to balance a part around its axis statically
Lapping Machine: Used for the lapping of surfaces, mostly for contact
sealing
Slotting Machine: Used to create keyways

Machinery Maintenance Ammonia-II:

This section deals with the Machinery components and holds the
responsibility of maintenance of all the machinery components of plant 2.
The machinery components include compressors, pumps, bearings etc.

Centrifugal Pumps:
Centrifugal pumps are used to transport
fluids by the conversion of rotational
kinetic energy to the hydrodynamic
energy of the fluid flow. The rotational
energy typically comes from an engine or
electric motor. The fluid enters the pump
impeller along or near to the rotating axis
and is accelerated by the impeller,
flowing radially outward into a diffuser or
volute chamber (casing), from where it
exits.
Common uses include water, sewage, petroleum and petrochemical
pumping; a centrifugal fan is commonly used to implement a vacuum

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cleaner. The reverse function of the centrifugal pump is a water turbine
converting potential energy of water pressure into mechanical rotational
energy.
Parts of Centrifugal Pump

Propeller Pump:
In the propeller pump a propeller can be driven
directly by a sealed motor in the pipe or by
electric motor or petrol/diesel engines mounted
to the pipe from the outside or by a right-angle
drive shaft that pierces the pipe.
Fluid particles, in course of their flow through the pump, do not change their
radial locations since the change in radius at the entry (called 'suction') and
the exit (called 'discharge') of the pump is very small. Hence the name
"axial" pump.

Stuffing Box:
A stuffing box is an assembly which is used to house
a gland seal. It is used to prevent leakage of fluid,
such as water or steam, between sliding or turning
parts of machine elements.

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Positive Displacement Compressor:
Positive displacement compressors draw in and capture a volume of air in a
chamber, then reduce the volume of the chamber to compress the
air. Reciprocating Piston Compressors, Rotary Screw Compressors, Rotary
Vane Compressors, and Scroll Compressors are all positive displacement
compressors.
Reciprocating Piston Compressors
Piston compressors are further divided into two
main categories – single acting and double acting.
Single Acting means that air is drawn in and
compressed on one side of the piston. The other side
is exposed to the crankcase of the compressor. In
this case, the downward stroke of the piston draws
in the air, and the upward stroke compresses it.
Double Acting reciprocating compressors have
compression chambers on both sides of the piston.
On the down stroke, air is drawn in on the top of the piston while air is
compressed on the bottom side. On the upstroke, air is drawn into the
bottom side while air is compressed on the top side. Double acting machines
require sealing of the piston rod, so a crosshead is used to eliminate the
angular movement of the rod

Rotary Screw Compressors:

Rotary screw compressors draw air and lubricant into a
void created as two helical rotors mesh together. Once the
rotors pass by the inlet port of the pump (called an airend),
the cavity decreases in size for the remainder of the
rotation, compressing the air-oil mixture.

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 Rotary Vane Compressors:
Rotary sliding vane compressors operate similar to an air
motor, with an off-center rotor turning sliding vanes. As the
vanes near the area where the distance between the rotor
and casing is small, the air is compressed.

Lobed compressor:
In this type of compressors air is entrapped between lobes and then
displace to the other end. As shown in fig.

Liquid Piston compressor:

In this type of compressor gar in entrapped
between the liquid ring and then got
compressed and discharged from the discharge
side.

Difference between positive and non-positive compressors

Positive Displacement Type:
In this type of compressors, air is physically trapped between to relatively
moving components and forced to occupy lower volume, thereby increasing
its pressure.

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Most notable example would be, a reciprocating compressor. In which air is
trapped between piston and cylinder volume and then literally pressed to
increase its pressure.
Non-Positive Displacement Type:
In this type, a rotating component imparts its kinetic energy to the air which
is eventually converted into pressure energy.
Centrifugal compressors are non-positive displacement type. Rotating
impeller imparts KE to the air which is converted to PE as air passes through
the diffuser.
The term 'positive displacement' emphasizes the fact that a volume is
physically being displaced, whereas there is no physical displacement in
centrifugal pumps.
Another point of interest is the output of these pumps. Since constant
volume is being displaced by the moving part every time, the flow output of
a positive displacement pump is always constant. Whereas, in non-positive
displacement type, the output fluctuates with the speed of rotation of
impeller (as there is nothing physically forcing the air through)

Bearings:
A bearing is a machine element that constrains relative motion to only the
desired motion, and reduces friction between moving parts

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Bearing Types and Application
There are many distinct bearing types, each with particular characteristics
which are suited to specific applications. Here are the four most common
types of bearings:
Ball Bearings
–Rolling function is provided by a ball
–Low friction, high speed, light to medium loading
–Light and general machine applications
Commonly found in fans, roller blades, wheel bearings, and
under hood applications on cars etc.
Cylindrical & Needle Roller Bearings:
Where the rolling function is provided by a cylinder of some
kind. May also be referred to as needle roller bearings (where
length is much greater than diameter)
-Low friction, medium to heavy radial loading
Commonly found in general machine applications including
gearboxes and transmissions, machine tool and construction
equipment.
Tapered Roller Bearings:
A tapered version of a roller bearing is used for combined axial
and radial loads, such as in wheel applications on trucks
Commonly found in heavy industrial, truck and wheel
applications with combined radial and axial loads. Some
examples are manual transmissions, gearboxes, power
generation and other process equipment.
Spherical Roller Bearings:
- A roller bearing that has a barrel shaped roller.

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- Medium friction, medium to heavy loads and misalignment
capabilities
- Generally used for very high load applications with
misaligned shafts to housings.
Commonly found in gearboxes, conveyors, pulp and paper
machines and other process equipment.

Health Safety and Environment:

Health safety is an important concern in every industrial environment. Every
industry follows some protocols to ensure the safety of the workers. Here
too at FFC some rules regarding safety have been created and are followed
strictly. These rules include using all the protective equipment required at a
specific workplace. Some other rules include wearing non-loose clothing
covering the whole body etc. Safety equipment is issued to every worker
according to the workplace he has to work in. Most common personal safety
equipment includes goggles, gas masks, safety shoes, safety helmet, and ear
protection. The areas where a specific equipment must be used are marked
with indications.
Environment protection is another goal that has to be achieved while
running a fertilizer plant. No untreated waste should exit the plant and
damage the environment. FFC follows all the rules and regulations for
environment safety. Besides this, FFC initiates and works upon special
projects to reduce hazardous emissions.

Conclusion:
Internship at FFC was a great learning experience. Here at FFC I got the
exposure to the real industrial work and got a chance to relate my formal
academic learning to practicality. I have had a brief overview of the
organizational structure of the company and the management system.
Besides, an overview of the equipment used in the plant through the
literature from the library helped a lot in improving the understanding.
Being a professional engineer FFC produced what is most important; the
professional attitude.

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